Preassembled door

ABSTRACT

A door of preassembled construction which includes an enclosed casing strengthened by box-like frame parts and a hinged door part having the door panel interlocked with a channel-defining door frame.

0 United States Patent 1191 1111 3,796,008

Eakin Mar. 12, 1974 [54] PREASSEMBLED DOOR 3,334,464 8/1967 Charles 49/501 X 2,824,630 2/I958 Tollma 52/620 [75] Invent Harold Eakm Double Sprmgs, 3,479,770 11/1969 Mock/ 49 501 3,690,037 9/1972 Kempel 1 49/380 Assignee: Mobile vista Industries, 3,703,063 ll/l972 Budich et a] 49/504 X Edwardsburg, Mich. FOREIGN PATENTS OR APPLICATIONS A g 10 114,857 9/1945 Sweden 419/380 PP N03 2791638 Primary Examiner-Mervin Stein Assistant ExaminerPhilip C. Kannan [52 us. c1 49/380, 49/504, 52/620 Attorney, Agent, & Knoblock [51] Int. Cl E06b 1/00 581 Field of Search 49/380, 501, 504, 505; I ABSTRACT 52/620, 621, 624, 615 A door of preassembled construction which includes an enclosed casing strengthened by box-like frame [56] References Cited parts and a hinged door part having the door panel in- UNITED STATES PATENTS terlocked with a channel-defining door frame.

7/1970 1 Claim, 5 Drawing Figures Gigante 49/504 X PAIENIEnm 2 m4 SHEET 1 [IF 2 PATENIEDMMZ m. 3796' 008 SHEEI 2 0F 2 PREASSEMBLEI) DOOR BACKGROUND OF THE INVENTION This invention relates to a door assembly and has specific application to a preassembled door which includes a door casing and door panel adapted for insertion into a doorway opening.

In constructing modular housing, mobile homes, travel trailers and similar structural devices, it is not uncommon for irregularities in wall construction to occur. Door assemblies heretofore utilized in such structural devices have been of light weight flexible construction which causes the casings of the assemblies to conform to the irregularities of the wall construction. This wall conformity of the door casings when utilizing preassembled or pre-hung doors causes binding of the doors and a poor fit between the casings and the door parts of the assemblies, with resulting water and air leakage around the door parts.

In this invention, the door assembly includes a casing which is shape retaining even when secured to an irregular side wall of a structural device and which in cooperation with a snug fitting, rigidly constructed door part forms a door substantially free from water and air leakage.

SUMMARY OF THE INVENTION The door assembly of this invention includes an enclosed casing and a door part hinged to the casing. The casing is constructed of parallel spaced side frame sections and parallel spaced upper and lower frame sections which are joined at their respective ends. Each frame section of the casing has a multiple-sided enclosed cross sectional configuration. The door part of the door assembly includes parallel spaced side frame parts and parallel spaced upper and lower frame parts which are each of a channel-shaped configuration and which receive a door panel. The marginal edges of the door panel fit within the channel-shaped door frame parts in an interlocking manner.

Accordingly, it is an object of this invention to provide a pre-hung door assembly which is of a rigid, shape-retaining configuration.

Another object of this invention is to provide a door of preassembled construction which includes a casing of an enclosed box-like cross sectional configuration, and a door part hinged to the casing which is of a multiple-part, rigid construction.

Still another object of this invention is to provide a door assembly which is of economical rigid construction and which can be installed into a structural device, such as a mobile home, modular house, or travel trailer in a simple and rapid manner.

Other objects of this invention will become apparent upon a reading of the inventions description.

BRIEF DESCRIPTION OF OF THE DRAWINGS A preferred embodiment of this invention has been chosen for purposes of illustration and description wherein:

FIG. 1 is a perspective view of the door assembly.

FIG. 2 is an enlarged fragmentary perspective view of that portion of FIG. 1 shown within the encircled portion 2 thereof.

FIG. 3 is a fragmentary sectional view taken along line 3-3 of FIG. 1.

FIG. 4 is a fragmentary sectional view taken along line 4-4 of FIG. 1.

FIG. 5 is a fragmentary sectional view of the lower edge of the door assembly of FIG. 1 shown attached to a structural frame with the door part of the assembly in its closed position.

DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred embodiment illustrated is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described in order to best explain the principles of the invention and its application and practical use to thereby enable others skilled in the art to best utilize the invention.

The illustrated door assembly includes a casing 10 and a door part 12. Hinges 14 connect door part 12 to casing 10 for opening and closing pivotal movement of the door.

Casing 10 is enclosed and includes spaced parallel side frame sections 16, upper frame section 18 and a lower frame section 20. Frame sections 16, 18 and 20 are preferably of an extruded construction and are joined at their respective end edges by suitable attachment means, such as screws, or by welding, or a bonding agent. Frame sections 16, 18 and 20 are preferably formed of aluminum or a similar metal composition and have a multiple-sided enclosed cross sectional configuration, preferably in the form of a four-sided box 22. Box 22 of each frame section 16, 18 and 20 extends the length 'of the frame section and provides the frame sections with strength and rigidity when in their assembled form.

Each frame section 16, 18 and 20 includes an inwardly projecting lip 24 and an outwardly projecting lip 26 which form an internal continual flange and an external continual flange respectively when the frame sections are assembled. As shown in FIG. 5, casing 10 is positioned in the door opening of the structural wall and may be secured thereto by suitable attachment means, such as screws (not shown), inserted through openings in the frame sections and turned into the underlying structural framework 28. Lips 26 of the assembled frame sections overlap the framework 28 of the door opening and, if desired, may carry a sealant strip 30 which serves to contact framework 28 and to form a peripheral seal about the door opening.

Door part 12 of the door assembly of this invention includes side frame parts 32, upper frame part 34 and a lower frame part 36. Frame parts 32, 34 and 36 may also be of an extruded construction and formed from aluminum or a similar metal composition. Each frame part 32, 34 and 36 is channel shaped in cross section, having side walls 40 joined by a connecting wall 38. Frame parts 32, 34 and 36 are preferably joined at their respective ends so. as to form an enclosed frame with a continuous internal channel.

The side walls 40 of each frame part 32, 34 and 36 include an undercut portion 42. Additionally, the connecting wall 38 of each frame part preferably carries opposed hooks 44 which extend the full length of the frame part and which are adjacently spaced from the undercut portion 42 of the side walls. A door panel 46, which may include a window therein, is fitted within frame parts 32, 34 and 36. Door panel 46 is preferably of a sandwich construction and includes an inner core 48, formed of a foamed polyurethane, polystyrene or similar plastic material, an inner thin-walled cover sheet 50 and an outer thin-walled cover sheet 52. Sheets 50 and 52 may be formed of aluminum or similar metallic sheet material. The marginal edges of door panel 46 fit between side walls 40 of each frame part 32, 34 and 36 with the outer edges 54 of cover sheets 50 and 52 lockingly engaging the undercut portions 42 of the frame part side walls. Core 48 of the door panel is bonded to cover sheets 50 and 52 and is formed around hooks 44 of each frame part. The bonded relationship between core 48 and cover sheets 50 and 52 in conjunction with the interlock between edges 54 of the cover sheets and undercut portions 42 of the side walls and the formation of the door panel core about hooks 44 of the frame parts serves to provide a rigid door panel construction.

To assemble door part 12, frame parts 32, 34 and 36 are mounted to a jig. Cover sheets 50 and 52 are inserted into position within the continuous channel formed by the frame parts and are held in such a posi-' tion by means ofsuitable back-up jigs. The edges of the cover sheets are positioned beteen the side walls 40 and adjacent hooks 44 of the frame parts. The unexpanded beads of the plastic foaming material is injected between the cover sheets 50 and 52 and foamed causing the cover sheets to be pressed against the back-up jigs with the edges 54 of the cover sheets being outwardly deformed under the influence of the expanding foam core into an interlocking relationship with the undercut portions 42 of the frame part side walls. Simultaneously, the core during foaming expands and forms around opposing hooks 44 of the frame parts. Once core 48 has been expanded and permitted to set, the holding and back-up jigs for the frame parts and cover sheets can be removed. To facilitate assembly of the frame parts for the forming of door panel core 48, it may be desirable to connect the joining ends of frame parts 32, 34 and 36 by means of screws or similar attachment means.

Frame parts 32, 34 and 36 each include an outer lip 56 which when the door panel is assembled forms a pcripheral exterior flange. Lips 56 of frame parts 32, 34

and 36 carry a flexible seal 58 which, when the door is in its closed position, makes peripheral sealing contact with frame sections 16, 18 and 20 of casing 10, as best illustrated in FIG. 5. A latch, spring, or similar securement means can be used to lock or hold door part 12 in its closed position. Additionally, a screen door part may be hinged to the casing of this invention for use in conjunction with the door part 12 above described.

It is to be understood that the invention is not to be limited to the details herein given but may be modified within the scope of the appended claims.

What I claim is:

1. A door of preassembled construction adapted for positioning in a doorway opening, said door comprising an enclosed casing and a door part hinged to said casing, said casing including parallel spaced side frame sections and parallel spaced upper and lower frame sections, said frame sections being joined at their respective ends, each frame section having a multiplesided enclosed box-like cross sectional configuration for imparting strength to said casing, said door part including parallel spaced side frame parts and parallel spaced upper and lower frame parts, each frame part having a channel shaped cross sectional configuration defined by two spaced side walls and a connecting wall, a panel carried by said frame parts and being formed ofa plastic foamed core sandwiched between inner and outer thin walled cover sheets, the marginal portions of said core and cover sheets being fitted between the side walls of said frame parts, said side walls of each frame part having opposed undercut portions, each frame part carrying opposed hook means for engaging the foamed core of said door panel, each hook means extending substantially the length of its frame part and being located adjacently spaced in an opposed relationship from the undercut side wall portion thereof, the marginal portions of said cover sheets and a portion of said core located compressibly between said hook means and opposed undercut side wall portions with said cover sheet being deformed and interlocking under said undercut side wall portions. 

1. A door of preassembled construction adapted for positioning in a doorway opening, said door comprising an enclosed casing and a door part hinged to said casing, said casing including parallel spaced side frame sections and parallel spaced upper and lower frame sections, said frame sections being joined at their respective ends, each frame section having a multiple-sided enclosed box-like cross sectional configuration for imparting strength to said casing, said door part including parallel spaced side frame parts and parallel spaced upper and lower frame parts, each frame part having a channel shaped cross sectional configuration defined by two spaced side walls and a connecting wall, a panel carried by said frame parts and being formed of a plastic foamed core sandwiched between inner and outer thin walled cover sheets, the marginal portions of said core and cover sheets being fitted between the side walls of said frame parts, said side walls of each frame part having opposed undercut portions, each frame part carrying opposed hook means for engaging the foamed core of said door panel, each hook means extending substantially the length of its frame part and being located adjacently spaced in an opposed relationship from the undercut side wall portion thereof, the marginal portions of said cover sheets and a portion of said core located compressibly between said hook means and opposed undercut side wall portions with said cover sheet being deformed and interlocking under said undercut side wall portions. 